2nd August 2021
The new Grundfos CR moves the limits for multistage pumps, energy efficiency is improved beyond all know limits and maximum working pressure on the standard pumps is increased to 40 bars. Introducing new flow sizes to 320 m3/h. Grundfos CR opens a new world of opportunities for vertical inline multistage pumps.
The new generation of Grundfos CR pumps are for engineers who like to move the limits.
Key Considerations and Life-Cycle Cost Framework
Purchase costs for different types of pumps used in water distribution and industrial pressure-boosting applications can vary significantly. Whether they are end-suction pumps, split-case pumps, or vertical lineshaft turbines, though, their price tag is only a small fraction of their total life-cycle cost.
Energy forms the largest single factor in pump life-cycle cost, ranging from 40 percent to as high as 90 percent depending on the pump style and application. That is why it makes sense to reevaluate traditional pressure-boosting pump selection in favour of total life-cycle performance costs, not simply initial purchase costs.
As with so many energy-intensive industry and municipal applications, there are two major ways to reduce total life-cycle costs:
- Start by identifying the most cost-effective pump designs for energy efficiency and maintenance simplicity.
- Operate them in a way that optimises energy consumption — e.g., through task-specific sizing and/or variable frequency drives (VFDs) that optimise load matching control.
Consider All Aspects of Lifecycle Costs
Whether the challenge at hand is to find a more economical replacement for an existing pressure-boosting operation or to evaluate the best options for an entirely new one, it pays to evaluate both the capital expense (CAPEX) and operational expense (OPEX) implications of those options. For many applications — such as small municipal utilities, isolated large developments, pressure zones in hilly terrain, industrial power washing, etc. — vertical multistage centrifugal inline pumps offer the best alternatives across a broad range of evaluation categories. Here are their key ROI attributes in terms of power consumption, maintenance, installation, performance, and responsiveness to variable flow and variable water pressure demands.
The new generation of large CR pumps has been made even more robust than its forerunners through use of state-of-the-art technology in simulation-design, materials, testing and production.
Reduced Energy Consumption
The new generation of Grundfos CR has been designed for maximum energy efficiency and performance across the board.
From the simulation-driven development of superior hydraulics to little innovations like profiling the leading edges of vanes and introducing a flow-guiding system to eliminate eddies and turbulence. The outcome is a pump range that offers truly world-class energy efficiency, beating its already outstanding forerunners out of the blocks.
With the new CR generation, which will also introduce three extra-large flow sizes, single energy-efficient vertical multistage centrifugal inline pump can output up to 320 m3/h in high-head applications ranging up to 40 m. The job-matched efficiency of their pump curves makes these pumps excellent choices for optimizing energy efficiency (Minimum Efficiency Index ≥ 0.70) across the entire range of rated output.
Not all pump styles require the same amount or type of maintenance. By their very design, vertical multistage centrifugal inline pumps offer labor and OPEX advantages as compared to end-suction and split-case pumps.
To make absolutely sure, we test all our CR pumps thoroughly before they are allowed to leave the factory.
New option for balancing out axial thrust, the Thrust Handling Device (THD) which uses discharge pressure to counterbalance axial thrust. Requiring no special bearings, the THD allows for use of standard motors and improves motor service life. THD is available for new CR models from 75 kW and above.
Unlike horizontal long-coupled centrifugal pumps or split-case pumps that use greased, metal ball bearings in the pump housing, vertically oriented multistage centrifugal inline pumps exert very little radial load on their bearings. Their pump shafts can use graphite or PTFE bearing materials that are lubricated by the water flowing through the pump. These bearings last for a long time without having to be greased or having the pump dismantled for maintenance.
Being able to replace the mechanical seals on a vertical multistage pump without having to remove the motor saves time, saves money, and eliminates alignment issues related to motor removal. The entire process can be achieved in about 20 minutes with one-piece shaftseal cartridges and can easily be handled by newer technicians with minimal training. That stands in contrast to older pump styles with more labor-intensive component seals or alignment issues that might require a highly experienced in-house technician or third party maintenance service.
Long-coupled pumps come with a recommended nine-step realignment process to be performed every time the motor is removed — ideally including a laser alignment to assure that it is properly positioned and free from vibration. Short-coupled vertical multistage centrifugal inline pumps that do not require motor removal eliminate that excessive realignment labor, saving many hours of effort and downtime over the life of the pump.
Pump Configuration and Installation Economies
The small footprint requirements and simplified mounting configurations of vertical multistage centrifugal inline pumps offer two additional levels of cost-saving convenience.
- Easy Retrofit
Being able to install multiple vertical pump units in a fraction of the space occupied by existing horizontally mounted pumps makes it easy to upgrade existing applications or configure new installations with limited floorspace. Equally important, the inline mounting format minimizes the amount of piping effort required to fit them into existing infrastructure.
- Low-Cost Installation
Small, simple, floor-mounted pedestals and inline piping designs require minimal added investment for installation. They do not require sweeping vertical piping runs like end-suction pumps do nor the construction of deep pits needed to accommodate inline piping for vertical turbine pumps. Horizontal mounting or special minimum footprint installation also available. And of course, the new CRs are also available as combined systems with dedicated CUE frequency converter and as boosters systems.
The new generation adds even more options to what was already the most modular pump program in the world – including higher pressure, lower NPSH and the use of standard motors.
Vibration generated by misalignment issues is one of the biggest pump-killers in pressure boosting applications, causing shortened seal life and potentially even shortened bearing life. Close-coupled vertical multistage centrifugal inline pumps that never require motor removal for maintenance minimize the opportunity for misalignment of shafts connecting the motors and pumps, greatly reducing opportunities for wear-inducing vibration.
The new 40 bar standard working pressure is ideally suited for applications like filtration, reverse osmosis and boiler feed and:
- Water pressure boosting (buildings, public/industrial water supply)
- Washing and cleaning systems (high pressure, CIP and industrial washing)
- Industrial processes in wide temperature range – including liquids such as acids, alkali, oils, flammables etc.
- Temperature control
- Boiler feed
- Mining, offshore, power plants, oil & gas, snow canons….
While physical design features — hydraulic efficiency, energy-efficient motors, profiled impeller vanes to reduce resistance, etc. — contribute toward OPEX saving potential, the ultimate performance of any pressure-boosting application depends on its ability to respond to changing application demands. Working closely with engineering experts can provide information and insight on the best ways to implement specific projects, whether that involves identifying a proper pump curve or utilizing variable frequency drives.
Depending on the maximum pressure and flow requirement, when working with Grundfos solutions, the VFD can either be an MGE motor or a panel-mounted CUE VFD. The MGE motor is available up to 22 KW, a VFD larger than 30 KW will be a panel mounted CUE VFD. Regardless of whether the VFD is an MGE motor or CUE, the Grundfos factory-loaded firmware includes the pump curve for the pumping end. What this means is that the VFD knows where the pump will run at best efficiency. Grundfos VFDs understand Grundfos pumps, so plant maintenance engineers will not need to trim the system for optimized operational efficiency. The VFD allows the pump to provide low-flow demands at system pressures over a wide operating range.
All CR pumps can be connected to a Communication Interface Unit (CIU) to enable communication with and data transfer to SCADA and BMS systems, and with the addition of predictive monitoring, the new Grundfos CRs will become virtually unstoppable.
GRUNDFOS iSOLUTIONS MONITOR – brings insights beyond the expected
The new GRUNDFOS iSOLUTION MONITOR is the next step for performance optimisation and reliability. Through real-time data collection, its continuously capable of spotting even the slightest sign that pumps or consumption behavior has changed.
The solution is available with connection to GRUNDFOS’ E-pumps or drives to capture performance measures and process optimisation opportunities, in addition to this the solution collects data on vibration level, liquid temperature and will be able to stop the pump in case of dry-running.
We believe that optimising performance in pump applications, needs even more insights, that’s why we have added a module for additional application sensors for any process critical inputs.
“With this new solution our customers will be able to install and onboard themselves on our cloud service, because we focused much of our efforts on user-friendliness and plug-and-play”, says Jens Skødt, Chief sales developer at Grundfos.
GRUNDFOS has in connection with the iSOLUTIONS MONITOR developed further on the well-known Grundfos GO remote application (Android and iOS) for commissioning and changes in settings via Bluetooth and a cloud based performance dashboard, the GRUNDFOS iSOLUTION Cloud.
Key advantages of GRUNDFOS iSOLUTIONS MONITOR include:
- Foresee any changes in consumption patterns – to prevent exceeded thresholds
- Add multiple measuring points – for a complete application overview
- Plug and play equipment – to reduce installation and integration time
- Support on application critical events – by Customer Success Management team
- Gain immediate insights – to improve productivity and system performance